A real-time welding quality control and assessment system

摘要

A welding quality control and assessment system has been gradually established at Brunei University. The system can not only control the weld penetration and follow weld seams but also detect welding defects in real-time by a multifunctional ultrasonic sensor. Some years ago, an ultrasonic sensor capable of monitoring and controlling weld penetration in weldments over 10 mm thickness was patented. Following that, simultaneous seam tracking was added by utilising the leading edge of the ultrasonic beam spread. 'Seam-following' accuracy of ±0.3 mm was found, whilst the device still controlled weld penetration in real-time at welding speeds in excess of 10 mm.s~(-1). By changing the ultrasonic probe type, penetration control in thin plate, using gas tungsten arc welding (GTAW), was possible. A real-time defect detection system, operating by the trailing edge of the ultrasound signal and examining the solidifying weld, was successfully incorporated into the existing system. As a result, the system became a real multifunctional welding quality control and assessment system.